I have the control valve rebuild kit for rear self leveling suspension on my '84 300tdt, but I cannot get one of the fittings off....I have used torch on the valve body, freon on the nut, flare nut wrench, pb blaster, and finally a vise grips, and that damn thing is stuck for good and now mangled!!!! I believe I will need to cut that line (one of the thicker return or supply lines) in order to remove the valve to rebuild it. Then I would like to flare the cut ends and re-connect with a connecting block.

Here is my question: the OD of that line is a hair above 6 mm and a hair under a quarter inch. I actually measure OD with calipers and compared to actual new 1/4 inch line, and the new 1/4 inch line was slightly bigger. Can I use a standard flare tool for quarter inch line to flare both ends and connect with block, or will the line slide in the flare tool (I have never used a flare tool before).

Also, I may just try to use a suage-type compression fitting, to reconnect both lines, but only if it is the return line (return line low pressure, supply line high pressure).

Any thoughts on the size of the tubing...is it Mercedes special, or standard???

Thanks,

Mark

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1984 300TD Wagon, 407,800 mi (current daily driver)
1985 300DT Sedan, 330,000 mi (gone to that great autobahn in the sky)

Which line is mangled? If it's one of the two that come out of the rear you shoud be able to remove the line from the accumulator. Then you can take the valve out with the mangled line still attached. This would make removing the line from the valve a little easier. And fixing the line easier as well.

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I wish it were that simple....the mangled/stubborn line is one of the supply/return lines from the front of the vehicle...

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1984 300TD Wagon, 407,800 mi (current daily driver)
1985 300DT Sedan, 330,000 mi (gone to that great autobahn in the sky)

Your flaring tool should be fine. Most have a variable grip when doing the flare procedure. Just make sure you have the proper size and thread pitch for the fittings. Never use the compression ring type connecters like you see at home depot used for water connections. This type is known for being leak prone.

You may need to have a throw away wrench welded to the fitting to finally get it off. I feel your pain on that one.

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RRGrassi


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